Ford Mustang (1999-2004) Service Manual: Installation

Using special tool 205-024

NOTE: This is the preferred method for installing the pinion bearing cups. If necessary, proceed to Using special tools 205-153, 205-024, 205-231, and 205-D055 in this procedure for an alternate method.

1. Position the special tools and the inner and outer pinion bearing cups in their respective bores.

1. After placing the inner and outer bearing cups in their bores, place the special tool on the inner bearing cup.

2. Place the special tool on the outer bearing cup.

3. Install the special tool.

Drive Pinion

2. Tighten the special tool to seat the pinion bearing cups in their bores.

Drive Pinion

3. CAUTION: Always install new differential pinion bearings when installing new pinion bearing cups.

NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.

Check that the cups have seated correctly in their bores.

Drive Pinion

Using special tools 205-153, -024, -231, and -D055

NOTE: This is an alternate method for installing the pinion bearing cups. Carry out this procedure if pinion bearing cup installation was not done in the previous steps.

4. Using the special tools, drive the outer differential drive pinion bearing cup into the differential housing.

Drive Pinion

5. Using the special tools, drive the inner rear axle pinion bearing cup into the differential housing.

Drive Pinion

6. CAUTION: Always install new differential pinion bearings when installing new pinion bearing cups.

NOTE: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the cup, remove and reseat the cup.

Check that the cups have seated correctly in their bores.

Drive Pinion

Setting pinion depth

7. NOTE: Apply only a light oil film on the differential pinion bearings before assembling the tools.

Assemble and position the following in the differential housing.

Setting pinion depth

 

Item Part Number Description
1 205-109 Adapter for 205-S127 (T76P-4020-A9)
2 205-105 Adapter for 205-S127 (T76P-4020-A3) (1.612 inch O.D.)
3 4630 Rear (inner) pinion bearing
4 205-129 Adapter for 205-S127 (T79P-4020-A18) (1.1884 inch thick)
5 205-110 Adapter for 205-S127 (T76P-4020-A10) (1.7 inch thick)
6 4621 Front (outer) pinion bearing
7 205-111 Adapter for 205-S127 (T76P-4020-A11)

8. NOTE: This step duplicates final differential pinion bearing preload.

Tighten the special tool to specification.

Setting pinion depth

9. NOTE: Offset the special tool to obtain an accurate reading.

Rotate the special tool several half-turns to make sure the differential pinion bearings seat correctly and position the special tool as shown.

Setting pinion depth

10. Install the special tool.

1. Position the special tool.

2. Install the bearing caps.

3. Install the four bolts.

Setting pinion depth

11. NOTE: Use only flat, clean drive pinion bearing adjustment shims (4663).

NOTE: Selection of too thick a shim results in a deep tooth contact at final assembly. Do not attempt to force the shim between the special tools. A slight drag indicates correct shim selection.

Use a drive pinion bearing adjustment shim as a gauge for shim selection.

  • After determining the correct shim thickness, remove the special tools.

Setting pinion depth

12. Position the correct thickness drive pinion bearing adjustment shim and the differential pinion bearing on the drive pinion gear. Using a suitable press and the special tools, press the differential pinion bearing until it seats firmly against the drive pinion gear.

Setting pinion depth

13. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.

Setting pinion depth

14. Install the outer differential pinion bearing.

Setting pinion depth

15. Install the rear axle drive pinion shaft oil slinger.

Setting pinion depth

16. Install the drive pinion assembly (drive pinion, shims, bearing, and the collapsible spacer) into the differential housing bore.

Setting pinion depth

17. NOTE: Coat the rear axle drive pinion seal lips with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.

Place the rear axle drive pinion seal on the special tool.

Setting pinion depth

18. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove it and install a new one.

Position the rear axle drive pinion seal in the seal bore, and use the special tool to drive the seal into place.

Setting pinion depth

19. Lubricate the pinion flange splines.

  • Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A.

20. NOTE: Disregard the index marks if installing a new pinion flange.

Position the pinion flange.

Setting pinion depth

21. Using the special tools, install the pinion flange.

Setting pinion depth

22. CAUTION: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to reduce preload, install a new collapsible spacer and nut.

CAUTION: Remove the special tool while taking readings with the Nm (inch-pound) torque wrench.

Tighten the nut to set the preload.

  • Rotate the drive pinion occasionally to make sure the differential pinion bearings seat correctly. Take frequent differential pinion bearing torque preload readings by rotating the drive pinion with a Nm (inch-pound) torque wrench.
  • For new differential pinion bearings, tighten the nut to specification. Refer to torque specifications for new differential pinion bearings in the Specifications portion of this section.
  • For used differential pinion bearings, if the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the nut to specification. Refer to torque specifications for used differential pinion bearings in the Specifications portion of this section.
  • For used differential pinion bearings, if the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the nut to the original reading as recorded.

Setting pinion depth

    Removal
    1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section. 2. CAUTION: Record the torque necessary to maintain rotatio ...

    Final assembly
    23. Install the differential assembly in the differential housing. For additional information, refer to Differential Case in this section. 24. CAUTION: Align the index marks. CAUTION: Install the d ...

    Other materials:

    Removal
    All vehicles 1. Remove the air intake scoop. For additional information, refer to Section. 2. Remove the Hydro-Boost brake booster. For additional information, refer to Section.. 3. Raise and support the vehicle. For additional information, refer to Section ...

    Recreational towing
    Note: Do not tow with the Shelby GT500 model. It cannot tow a trailer. Note: Do not exceed the trailer weight for your vehicle configuration listed in the chart below. Note: Make sure to take into consideration trailer frontal area. Do not exceed 12 feet2 (1 ...

    Assembly
    1. Lubricate all components with the recommended transmission fluid when reassembling. 2. Using the special tools, press the output shaft front bearing on the output shaft. 3. Install the third gear bearing. Apply petroleum jelly to the bearing. 4. I ...